Method of alkylating phenols



Patented Aug. 2, 1938 UNITED sTATEs PATENT orrlca METHOD OF ALKYLATING I'HENOLSv No Drawing.

Application May 1, 1936,

Serial No. 77,383

I Claims.

This invention concerns an improved method oi alkylating phenols with alcohols containing 6 or more carbon atoms,

Two general methods of alkylating a phenol with an alcohol are known, via: (1) by warming a mixture of a phenol and alcohol with a large excess of sulphuric acid to temperatures in the neighborhood of 40-70 C., and (2) by heating a mixture of a phenol and alcohol with a, small proportion of a catalyst, such as an acid-activated bleaching earth, to a temperature above 200 C. under pressure. Each of these methods involves certain disadvantages. The first method is costly, since it involves the use of sulphuric acid in amount representing several times the combined weight of the phenol and alcohol. Furthermore, the yields reported by this method are generally low, usually not exceeding 50 per cent of theoretical (see Meyer et al., Monatsh, 53-54, 721-752 (1929) The second method is hazardous, since it involves heating materials which are both toxic and inflammable under high pressure. Also, water formed by the reaction is retained in the mixture and tends to retard further reaction and prevent the same from running to completion.

An object of the present invention is to provide a method of alkylating a phenol with an alcohol, whereby the reaction may be carried out at a moderate pressure in the presence of only a small proportion of catalyst, water being removed from the reacting mixture as it is formed, to produce alkyl phenols in high yield. Other objects will be apparent from the following description of the invention.

I have found that, when an alcohol containing at least six. carbon atoms is employed as the alkylating agent, the reaction may be, carried out at approximately normal pressure simply by heating a mixture of the phenol and such alcohol with 4 l a small proportion of catalyst to a temperature at which the alcohol is decomposed into an oleilne and water, while distilling off the water as it is formed. A portion of the oleflne distills off along with the water, but such oleflne may be removed as a separate layer from the aqueous distillate and returned to the principal reaction. By operating in this cyclic manner, the employment of a large proportion of catalyst is avoided,

' the oleflne formed as an intermediate product 59 serves as an assistant in removing water from the reaction by forming a relatively low boiling mixture with thewater, and an alkyl phenol may be producedin higher yield than is possible by either of the previously known methods of carrying out the reaction hereinbefore described. A

large number of alkyl phenols have been prepared according to the foregoing method, among which are compounds useful as germicides, fungicides, insecticides, etc. The invention, then, conv sists in the method hereinafter fully described and particularly pointed out in the claims.

The alcohol employed in the process is one having at least 6 carbon atoms and which can be dehydrated to form an oleflne. It may be a primary, secondary, or tertiary alcohol and may be of the aliphatic, alicyclic, or aralkyl type. Such alcohol usually can be decomposed catalytically under atmospheric pressure at a temperature below its boiling point to form water and a water-immiscible liquid olefine which forms a low boiling mixture with the water, thereby aiding in removal of the latter by distillation, and which can be separated directly from the water in the distillate and returned to the reaction. The alcohols containing less than six carbon atoms usually must be heated under pressure or at a temperature above their boiling point in order to decompose the same into anoleflne and water and the oleflne so produced is usually a gas or a low boiling liquid which does not aid greatly in distilling water from the reacting mixture and which is relatively difllcult to handle in the process. Among the various alcohols which may satisfactorily be used are: n-hexyl alcohol, secondary hexyl alcohol, tertiary hexyl alcohol, cyclohexanol, lauryl alcohol, cetyl alcohol, alphaphenylethyl alcohol, beta-phenylethyl alcohol, phenylpropyl alcohol, etc.

The phenolic reactant may be a monohydric or polyhydric phenol which may contain nuclear substituents such as alkyl or halogen groups, etc., provided one or more positions in the nucleus are open for the introduction of an alkyl group by the reaction. Among the various phenolic compounds which may be used are: phenol, ortho chlorophenol, para bromophenol, cresol, chlorocresol, naphthol, ortho-phenylphenol,paraphenylphenol, etc. In general, any phenol which can be alkylated to form a corresponding alkyl phenol by reaction with an olcfine can be employed in the present process.

A stable catalyst of the dehydration and condensation type is used, since the function of the catalyst is to promote dehydration of the alcohol in liquid phase and chemical condensation of the resultant oleflne with the phenol. By a stable" catalyst I mean one which is not destroyed by the water formed in the reaction, 1. e., if the catalyst is a material which forms a hydrate, it should be capable of being regenerated from such hydrate by heating the latter. Among the catalysts which grams (0.49 mole) of normal hexyl alcohol,

may be employed in the process are acid activated bleaching earths such as Tonsil and Superfiltrol,

;The water and, unreacted oleflne are, distilled from the mixture, and the oleilue is separated from water in the distillate and returned to the reaction. The reactants and catalyst may .be employed in widely varying proportions and may be mixed priorgto or during heating. In practice I prefer to treat the phenolic reactant with a small proportion, e. g., from 1 to 10 and preferably from 2 tr; 4 per cent of its weight, of the catalyst, heat the mixture to the reaction tem- E perature, and slowly add one molecular equivalent or more of the alcohol, preferably with stirring.

The temperature 'tojwhich the mixmre must be heated in order to dehydrate the alcohol varies somewhat depending on the particular alcohol and catalyst employed. The dehydration usually occurs smoothly at temperatures between 100 and 290 C., particularlybetween 130 and 2002C.

In practice, the mixture is usually heated at atmospheric pressure to a temperature between 100 and its boiling point, but it may be heated under a moderately elevated ipressure, e. g. 1-4 atmospheres pressure, at a considerably higher temperature, e. g., 250 0., without detriment. However, due to the difliculty of distilling water and the olefine from the mixture under pressure,

the reaction is preferably carried out at atmospheric pressure and may sometimes advantageously be carried out under'vacuum.

Operation in the cyclic manner jllSt describedis preferably continued until distillation of water or olefine from the reactiom mixture practically ceases. The mixture is then. cooled, the catalyst is free for substitution. The alkyl phenol in general corresponds to the alcohol and phenol from which it was formed, but when certain higher alcohols are employed asreactants, the allthe same.

the catalyst, or it may be separated and added to a subsequent reaction mixture, in .which it acts by mass action to prevent further formation of The following examples describe a number of ways in which the principle of the invention has been applied, but are not to be construed as limiting the invention.

7 Example 1- I A mixture of 46 4 grams (4.73 moles) ofgphenol,

and 47.8 grams of Zilonsil (an acid-activated bleaching earth) was heated at atmospheric pressure to 174 (3., at which temperature water and hexene started to distill. Hexene in the distillate was separated continuously from thewater and returned to the reaction. During the first 2 hours, 76.5 grams (0.76 mole) of additional normal hexyl alcohol was added withstirringr The operation. was continued for an additional 2 hours, i. e., until a total of 20 cubic centimeters of water had been collected, the temperature being raised from 174 to 189 C. The mixture was then cooled, filtered, and distilled. "There was obtained 163.3 grams of a mixture of isomeric hexyl phenols distilling at temperatures between 132 and 366 C. under 25 millimeters pressure; No hexyl phenyl ether was obtained. The yield of hexylphenols was 73 per cent of :theoretical, based 0 the hexyl alcohol employed;

Example 2 A mixture of 282 grams (3 moles) of phenol, grams; (1 mole) of cyclohexanol, and 8.5 grams of Retrol (an acid-activated blea s earth) was heated with stirring to .143 (3., at which temperature cyclohexene and water started to distill. The cyclohexene in the distillate was separated continuously from the water and returned to the reaction. The temperature of the reaction mixture was raised to 175 C. in approximately 1 hour, by which time the distillation of water and; cyclohexene had ceased, and the mixture was maintained at approximately 175 C. for an additional 2 hours, after which it was cooled, filtered and distilled. There was obtained 197.3 grams. (2.1 moles) of unreacted phenol, 135 grams (0.77 mole) of a mixture of orthoand para-cyclohexylphenols ccntaining approximately 59 per cent of the ortho-isomer, and 19.3 grams of higher boiling' jproducts. The yield of cyclohexylphenols was per cent of theoretical, based on the phenol reacted.

Example 3- A mixture of 220 grains (2 moles) of .catechol, 100 grams (1 mole) of cyclohexansl, and .11 grams of Tonsil (an acid-activated bleaching earth) was heated with stirring at atmospheric pressure, water and cyclc'nexene being distilled :from the mixture, and theicyclohexene in the distillate con tinuously separated-and returned to the reaction: The distillation started when the temperatureyield thereof being approximately 53 per cent of theoretical, based on the cyclohexanol employed.

The mixture of cyclohexyl-catechols was free; tionally crystallized successively from benzene and carbon tetrachloride whereby the following compounds were separatedz-(l) a monocyclohexyl-catechol meltinggat 107.8-l08.6 CL (uncorrected) believed to be 4-cyclohexyl-catechol, and

. (2) an isomeric monocyclohexyl-catechol, melting at 1415-1425 C. (uncorrected), which is believedato be 3-cyclohexyl-catechol. 1

Example 4 A mixture of 576 grains s moles) of betanaphthoi, 200 grams (2 moles) of cyclohexanol,

and 29 grams of Superflltrcl (an acid-activated bleaching earth) was reacted as in Example 3, The reaction started at 138 C., and was completed at 193 C. The reacted mixture was filtered and fractionally distilled, whereby there were obtained approximately 290 grams of unreacted beta-naphthol, approximately 295 grams of a mixture of isomeric cyclohexyl-beta-naphthols distilling at temperaturesbetween 227 C. under 20 millimeters pressure and 198 C. under 3 millimeters pressure, and 47 grams of higher products, probably dicyclohexyl-beta-naphthols.

distilling at temperatures between 238 and 252 was separated in the form of a white microcrystalline powder, and another monocyclohexylbeta-naphthol melting at 14:5.5-44'1 C., believed to be 6-cyclohexyl-2-naphthol having the formula was separated in the form or white lustrous line needles. Said products are useful as germieides, fungicides, and insecticides.

Example 5 A mixtureof 566 grams (3.9 moles) of alphanaphthol, 200 grams (2 moles) oi cyclohexanol, and 29 grams of Retrol was reacted as in Example 3. The reaction started at 141' C. and was completed at 185 C. The reacted mixture was filtered and fractlonally distilled, whereby 328.1 grams of a mixture of isomeric monocyclohexylalpha-naphthols was separated. The mixture of isomers was fractionally'crystallized successively from cyclohexene and petroleum'ether whereby,

the following compounds were separated: (1) a white crystalline compound melting at 98.8-99.1 0., believed to be 2-cyclohexyl-1-naphthol having the formula -COUu and (2) a white crystalline compound melting at 1403-1411? (2., believed to be 4-cyclohexyl-1- naphthol having the formula (Jenn Bald compounds are useful as germicides, fungicldes. and insecticides.

Other modes of applying the principle of the invention may be employed instead of those explained, change being made as regards the method or compounds herein disclosed, provided the steps or compounds stated by any of the following claims or the equivalent of such stated steps or compounds be employed.

1' therefore particularly point out and distinctly claim as my invention:

1. In a method of alkylating aphenol by heating the latter with a monohydric alcohol containing at least six carbon atoms in the presence of an acid activated bleaching earth, the steps which consist in distilling water and an oleflne from the reacting mixture, separating the water and olef'ine in the distillate, and returning the olefine to the reaction.

2. The method of alkylating a phenol which comprises heating a mixture of the phenol, a monohydric alcohol containing at least six carbon atoms, and an acid activated bleaching earth at approximately atmospheric pressure to a temperature at which water and an olefine distill therefrom, separating the water and oleiine in the distillate, andreturning the olefine to the reaction.

3. The method of alkylating a phenol which comprises heating the phenol with between about 1 and about 10 per cent its weight of an acid activated bleaching earth, gradually adding to the mixture a monohydric alcohol containing at least six carbon atoms, distilling from the mixture at approximately atmospheric pressure water and an olefine, separating the water and olefine in the distillate, and returning the oleflne to the reaction.

4. The method of alkylating a phenol which comprises heating at approximately atmospheric pressure a mixture of the phenol, a monohydric alcohol containing at least six carbon atoms, and an acid-activated bleaching earth in amount representing between about 2 and about 4 per cent the weight of the phenol to a temperature at which water and an olefine distill from the mixture, separating the water and olefine in the distillate, and returning the olefine to the reaction.

5. The method of alkylating phenol which comprises heating a mixture of phenol and a monohydric alcohol containing at least six carbon atoms with a small proportion of an acid activated bleaching earth at approximately atmospheric pressure to a temperature at which water and an oleflne distill from the mixture, separating the water and oleflne in the distillate,

and returning the olefine to the reaction.

separating the water and cyclohexene in the. 

